Gas Premix Burner Fuel Undersupply Detection and Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Gas premix burners face operational issues due to fuel gas undersupply, leading to reduced performance, increased pollutant emissions, and potential shutdowns, caused by mismatched fuel gas connection conditions such as insufficient line cross-sections or low supply pressure, resulting in improper fuel gas concentration and air ratio.
Innovation Solution
The method involves monitoring fuel gas supply using a pressure monitor or ionization electrode to detect undersupply, adjusting heat output and blower speed to maintain safe operation, and implementing output limitations to prevent excessive fuel gas throughput, with automatic or manual intervention to restore full nominal output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the fuel gas throughput is increased to meet higher heat output requirements, then the heat output is improved, but fuel gas undersupply occurs due to insufficient line cross-sections or low supply pressure, leading to improper fuel gas concentration and air ratio
Solution Approach 1:
The patent applies preliminary action by detecting fuel gas undersupply conditions before they lead to malfunction. The control unit continuously monitors fuel gas concentration or air ratio and identifies undersupply situations in advance, then proactively limits the heat output to prevent flaming flames, partial extinguishing, or complete shutdown. This anticipatory approach ensures reliable operation by avoiding the harmful effects of fuel gas undersupply.
2Productivity
If the fuel gas concentration is increased to maintain proper air ratio, then the combustion efficiency is improved, but the risk of flaming flames and increased pollutant emissions increases due to fuel gas undersupply
Solution Approach 1:
The patent implements feedback control by continuously monitoring the fuel gas concentration or air ratio and using this information to adjust the heat output. The control unit receives feedback from sensors that measure the actual fuel gas-air mixture composition and compares it with the desired values. When fuel gas undersupply is detected, the system automatically limits the heat output to maintain proper combustion conditions, thereby preventing flaming flames and reducing pollutant emissions while preserving combustion efficiency.
3Productivity
If the burner operates at maximum nominal output continuously, then the productivity is improved, but the burner may malfunction or shut down due to fuel gas undersupply under varying connection conditions
Solution Approach 1:
The patent applies dynamics by making the heat output adaptable and variable rather than fixed at maximum nominal output. The control unit dynamically adjusts the heat output based on real-time monitoring of fuel gas concentration or air ratio. When fuel gas undersupply is detected, the system automatically reduces the heat output to a safe level, preventing burner malfunction or shutdown. This dynamic adjustment ensures the burner operates reliably under varying fuel gas connection conditions while maintaining high productivity when conditions permit.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures trouble-free burner operation by maintaining stable fuel gas concentration, reducing pollutant emissions, and preventing burner malfunctions by detecting and addressing fuel gas undersupply, thereby ensuring consistent performance and safety.
Implementation Method 1
the fuel gas supply is monitored with the aid of a pressure monitor in the gas path, with the burner control detecting a possible drop below a gas pressure threshold value present at the pressure monitor
Implementation Method 2
an alternative or supplementary, second embodiment is based on monitoring the fuel gas supply using an ionization electrode in the flame, with the burner control detecting a possible drop below an ionization current threshold value present at the ionization electrode
Implementation Method 3
a variable-speed combustion air fan, which is controlled according to the currently required heat output
Implementation Method 4
They represent a central component of a gas heater and are used to provide and burn a combustible gas-air mixture to generate a hot combustion or exhaust gas stream
Data Source
AI summary
The method involves monitoring the gaseous fuel supply and detecting the actual gaseous fuel undersupply. The available heating power and blower speed is determined before the detected fuel gas undersupply during the burner operation and is placed in data storage of the burner regulation. The determined heating power and blower speed during the subsequent burner starting process or subsequent burner operation phase is considered as maximal realized and reduced heating output and blower speed.